System and method of forming at least a portion of a reinforced roof structure from sandwich panels

ABSTRACT

A roofing system includes a first sandwich panel, a second sandwich panel and a support panel. The first sandwich panel, which forms at least a portion of the roof structure, has a first outer layer and a second outer layer spaced from the first outer layer by a panel core. The first sandwich panel includes a first angle edge, which includes an edge portion of the panel core and an edge portion of at least the first outer layer. The second sandwich panel includes a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the edge portion of the first sandwich panel is supported, at least in part, by one or more outer surface Depending on the length of the roofing system and/or other design criteria, the roofing system includes one or more support panels secured between the first sandwich panel and the second sandwich panel to provide additional support for the roof structure.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to constructing buildings, and more particularly, to a roofing system for reinforcing and/or stiffening at least a portion of a roof structure formed from one or more composite sandwich panels.

DESCRIPTION OF THE RELATED ART

There is an increasing global demand for lower-cost buildings such as houses, warehouses and office space. The demand for lower cost buildings is particularly strong in developing countries where economic resources may be limited and natural resources and raw materials may be scarce. For example, in areas of the Middle East or Africa, conventional building materials such as cement, brick, wood or steel may not be readily available or, if available, may be very expensive. In other areas of the world, poverty may make it too costly for people to build houses or other buildings with conventional materials.

The demand for lower-cost housing also is high in areas afflicted by war or natural disasters, such as hurricanes, tornados, floods, and the like. These devastating events often lead to widespread destruction of large numbers of buildings and houses, especially when they occur in densely populated regions. The rebuilding of areas affected by these events can cause substantial strain on the supply chain for raw materials, making them difficult or even impossible to obtain. Furthermore, natural disasters often recur and affect the same areas. If a destroyed building is rebuilt using the same conventional materials, it stands to reason that the building may be destroyed or damaged again during a similar event.

It is generally desirable to increase speed of construction and to minimize construction costs. Prefabricated or preassembled components can streamline production and reduce both the time and the cost of building construction. Prefabricated buildings, however, are made from conventional materials and may be scarce or expensive to obtain. Thus, there exists a need for alternative materials and techniques for constructing buildings that use advanced material technologies to increase the speed of construction and also reduce or lower ownership costs.

SUMMARY

The present invention provides an alternative to conventional construction materials and techniques. Buildings, such as houses, commercial buildings, warehouses, or other structures can be constructed by composite sandwich panels (also referred to as “sandwich panels” or “composite panels” or “panels”), which have an insulative core and one or more outer layers. The buildings can be constructed by gluing several sandwich panels together, and usually traditional fasteners, such as screws, rivets, nails, etc., are not needed for such connections. Generally, composite sandwich panels offer a greater strength-to-weight ratio than traditional materials that are used by the building industry. The composite sandwich panels are generally as strong as, or stronger than, traditional materials including wood-based and steel-based structural insulation panels, while being lighter in weight. Because they weigh less than traditional building materials, the handling and transport of composite sandwich panels is generally less expensive. The composite sandwich panels also can be used to produce light-weight structures, such as floating houses, mobile homes, or travel trailers, etc.

Sandwich panels generally are more elastic or flexible than conventional materials such as concrete, steel or brick and, therefore, monolithic buildings made from sandwich panels are more durable than buildings made from conventional materials. For example, sandwich panels also may be non-flammable, waterproof and very strong and durable, and in some cases able to resist hurricane-force winds (up to 300 Kph (kilometers per hour)). The panels also may be resistant to the detrimental effects of algae, fungicides, water, and osmosis. As a result, buildings constructed from sandwich panels are better able to withstanding earthquakes, floods, tornados, hurricanes, fires and other natural disasters than buildings constructed from conventional materials.

Sandwich panel structures may be less expensive to build than structures built from conventional materials because of reduced material costs and alternative construction techniques. The ownership and maintenance costs for sandwich panel structures also may be less over the long term because sandwich panel structures may last longer and degrade at a slower rate than buildings made from conventional materials. Structures built from sandwich panels therefore may require less maintenance and upkeep than structures built from conventional building materials, which may reduce the overall ownership costs for end users.

The insulative core of the sandwich panels also may reduce the amount of energy needed to heat and/or cool the building, which may reduce the overall costs to operate the building. The insulative core also may reduce or eliminate the need for additional insulation in the building, as may be necessary to insulate structures built from conventional building materials. Sandwich panel structures therefore may be less expensive to build and operate than buildings constructed from conventional building materials.

Due to the elasticity and flexibility of the sandwich panels, in some instances it may be desirable to provide additional support to at least a portion of the structure. The additional support may be provided by securing one or more support panels between the sandwich panels that form the roofing structure and one or more base sandwich panels that support the roof structure.

One aspect of the invention relates to a roofing system including one or more support panels between a sandwich panel or panels that form at least a portion of the roof structure and a second sandwich panel or panels that support the roof structure. A bonding material is applied between the first sandwich panel and the second sandwich panel to secure the support panels in the desired location or locations.

One aspect of the invention relates to a roofing system including: a first sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core and a first angle edge including an edge portion of the panel core and an edge portion of at least the first outer layer, wherein the first sandwich panel forms at least a portion of a roof structure; a second sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the edge portion of the first sandwich panel is supported, at least in part, by one or more outer surface of the second sandwich panel; and one or more support panels secured between the first sandwich panel and the second sandwich panel to provide support for the roof structure.

Another aspect of the invention relates to a method of manufacturing a roof structure with one or more support panels, the method including: providing a roofing panel that includes a first outer layer and a second outer layer spaced from the first outer layer by a panel core and a first angle edge including an edge portion of the panel core and an edge portion of at least the first outer layer, wherein the roofing panel forms at least a portion of a roof structure; supporting the roofing panel with a base sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the base sandwich panel is secured to an associated structure; and securing one or more support panels between the roofing panel and the base panel to provide support for the roof structure.

These and further features of the present invention will be apparent with reference to the following description and attached drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. Rather, the invention includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto.

It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with, or instead of, the features of the other embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of an exemplary roofing system in accordance with aspects of the present invention.

FIG. 2 is an isometric view of an exemplary sandwich panel.

FIG. 3 is a sectional view of an exemplary roofing system in accordance with aspects of the present invention.

FIG. 4 is a sectional view of the exemplary roofing joint looking generally in the direction of line 4-4 of FIGS. 1 and 3 in accordance with aspects of the present invention.

FIG. 5 is a sectional view of an exemplary roofing system in accordance with aspects of the present invention.

FIG. 6 is an environmental view of an exemplary monolithic structure built from composite materials in accordance with aspects of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

In the detailed description that follows, like components have been given the same reference numerals regardless of whether they are shown in different embodiments of the invention. To illustrate the present invention in a clear and concise manner, the drawings may not necessarily be to scale and certain features may be shown in somewhat schematic form. Certain terminology is used herein to describe the different embodiments of the invention. Such terminology is used only for convenience when referring to the figures. For example, “upward,” “downward,” “above,” or “below” merely describe directions in the configurations shown in the figures. The components can be oriented in any direction and the terminology should therefore be interpreted to include such variations. Furthermore, while described primarily with respect to house construction, it will be appreciated that all of the concepts described herein are equally applicable to the construction of any type building, such as warehouses, commercial buildings, factories, apartments, etc.

The structures described herein are built with composite materials, such as composite sandwich panels (referred to herein as “sandwich panels”). Sandwich panels, which may be formed from synthetic materials, provide a light-weight and less expensive alternative to conventional raw materials, e.g., wood, concrete, metal, etc. Sandwich panels are usually connected or joined together with a high-strength bonding material, such as epoxy or glue, and conventional materials, such as nails and screws, are not usually needed. The result is a strong and durable monolithic (e.g., single unit) structure, as described further below.

Referring to FIG. 1, a sectional view of an exemplary roofing system 10 is illustrated. The roofing system 10 may be part of a monolithic structure 12 (e.g., a house), as discussed below. The roofing system 10 includes a first sandwich panel 14 that forms an exterior portion of the roof, a second sandwich panel 16 that supports the roof structure and a support panel 18 that provides additional support to one more sandwich panels that form the roof structure.

The first sandwich panel 14, which forms at least a portion of the roof structure, has a first outer layer 20 and a second outer layer 22 spaced from the first outer layer 20 by a panel core 24. The first sandwich panel 14 includes a first angle edge 26, which includes an edge portion 28 of the panel core 22 and an edge portion 30 of at least the first outer layer 20.

The second sandwich panel 16 includes a first outer layer 32 and a second outer layer 34 spaced from the first outer layer 32 by a second panel core 36, wherein the edge portion 26 of the first sandwich panel 14 is supported, at least in part, by one or more outer surface (e.g., first outer surface 32) of the second sandwich panel 16.

Depending on the length of the roofing system 10 and/or other design criteria, the roofing system 10 includes one or more support panels 18 secured between the first sandwich panel 14 and the second sandwich panel 16 to provide additional support for the roof structure. The one or more support panels 18 are positioned under the roof and may be referred to herein as “under-roof” construction. The support panels 18 may be designed as vertical ribs under one or more first sandwich panels 14 that form a portion of the roof structure. The distances of the support panels 18 may be in accordance with the static calculation, which is based on the load/construction requirement set by a municipality or law. Another design consideration is whether user access to the roof is necessary, which may impact how and where the support panels are attached to the roof structure. The support panels 18 may be affixed by filling one or more corners formed between the sandwich panel that forms the roof structure and the support panels 18 with bonding material 38 (e.g., glue or other suitable adhesive). For static designs, a continuous layer of bonding material 38 is not needed, which saves bonding material resources and costs associated therewith. The sandwich panels that form the roof structure may also be finished and/or coated with a water protection to prevent moisture from damaging the sandwich panels and/or the structure 12.

Referring to FIG. 2, an exemplary sandwich panel 50 is illustrated. As used herein, the phrase “sandwich panel” means a panel having two outer layers 52, 54 separated by a core 56. The outer layers 52, 54 of the sandwich panel 50 are made from a composite material that includes a matrix material and a filler or reinforcement material. Exemplary matrix materials include a resin or mixture of resins, e.g., epoxy resin, polyester resin, vinyl ester resin, natural (or non oil-based) resin or phenolic resin, etc. Exemplary filler or reinforcement materials include fiberglass, glass fabric, carbon fiber, or aramid fiber, etc. Other filler or reinforcement materials include, for example, one or more natural fibers, such as, jute, coco, hemp, or elephant grass, balsa wood, or bamboo.

The outer layers 52, 54 (also referred to as laminates) may be relatively thin with respect to the panel core 56. The outer layers 52, 54 may be several millimeters thick and may, for example, be between about 1 mm (millimeter)—12 mm (millimeters) thick; however, it will be appreciated that the outer layers can be thinner than 1 mm (millimeter) or thicker than 12 mm (millimeters) as may be desired. In one embodiment, the outer layers are about 1-3 mm (millimeters) thick.

It will be appreciated that the outer layers 52, 54 may be made thicker by layering several layers of reinforcement material on top of one another. The thickness of the reinforcement material also may be varied to obtain thicker outer layers 52, 54 with a single layer of reinforcement material. Further, different reinforcement materials may be thicker than others and may be selected based upon the desired thickness of the outer layers.

The panel core 56 separates the outer layers 52, 54 of the sandwich panel 50. The panel core 56 may be formed from a light-weight, insulative material, for example, polyurethane, expanded polystyrene, polystyrene hard foam, Styrofoam® material, phenol foam, a natural foam, for example, foams made from cellulose materials, such as a cellulosic corn-based foam, or a combination of several different materials. Other exemplary panel core materials include honeycomb that can be made of polypropylene, non-flammable impregnated paper or other composite materials. It will be appreciated that these materials insulate the interior of the structure and also reduce the sound or noise transmitted through the panels, e.g., from one outer surface to the other or from an exterior to an interior of a building structure, etc. The panel core 56 may be any desired thickness and may be, for example, 30 mm (millimeters)—100 mm (millimeters) thick; however, it will be appreciated that the core can be thinner than 30 mm (millimeters) or thicker than 100 mm (millimeters) as may be desired. In one embodiment, the core is approximately 40 mm (millimeters) thick.

The outer layers 52, 54 are adhered to the core 56 with the matrix materials, such as the resin mixture. Once cured, the outer layers 52, 54 of the sandwich panel 50 are firmly adhered to both sides of the panel core 56, forming a rigid building element. It will be appreciated that the resin mixture also may include additional agents, such as, for example, flame retardants, mold suppressants, curing agents, hardeners, etc. Coatings may be applied to the outer layers 52, 54, such as, for example, finish coats, paint, ultraviolet (UV) protection, water protection, etc.

The panel core 56 may provide good thermal insulation properties and structural properties. The outer layers 52, 54 may add to those properties of the core and also may protect the panel core 56 from damage. The outer layers 52, 54 also may provide rigidity and support to the sandwich panel 50.

The sandwich panel 50 may include a first edge 58, a second edge 60, a third edge 62 and a fourth edge 64. The sandwich panels may be any shape and size. In one embodiment, the sandwich panels are rectangular in shape and may be several meters, or more, in height and width. The sandwich panels also may be other shapes and sizes. The combination of the panel core 56 and outer layers 52, 54 create sandwich panels with high ultimate strength, which is the maximum stress the panels can withstand, and high tensile strength, which is the maximum amount of tensile stress that the panels can withstand before failure. The compressive strength of the panels is such that the panels may be used as both load bearing and non-load bearing walls. In one embodiment, the panels have a load capacity of at least 50 tons per square meter in the vertical direction (indicated by arrows V in FIG. 2) and 2 tons per square meter in the horizontal direction (indicated by arrows H in FIG. 2). The sandwich panels may have other strength characteristics as will be appreciated in the art.

Internal stiffeners may be integrated into the panel core 56 to increase the overall stiffness of the sandwich panel 50. In one embodiment, the stiffeners are made from materials having the same thermal expansion properties as the materials used to construct the panel, such that the stiffeners expand and contract with the rest of the panel when the panel is heated or cooled.

The stiffeners may be made from the same material used to construct the outer layers of the panel. The stiffeners may be made from composite materials and may be placed perpendicular to the top and bottom of the panels and spaced, for example, at distances of about 15 cm (centimeters), 25 cm, 50 cm, or 100 cm. Alternatively, the stiffeners may be placed at different angles, such as a 45-degree angle with respect to the top and bottom of the panel, or at another angle, as may be desired.

FIG. 3 illustrates a sectional view of roofing system 70. Roofing system 70 is similar to roofing system 10 illustrated in FIG. 1, except that roofing system 70 illustrates the bonding material 38 as a continuous layer of bonding material applied between the sandwich panels 14, 16 and the support panel 18. A continuous layer of bonding material 38 provides additional stiffness to the roofing system 70. A continuous layer of bonding material 38 may be desired depending on the design and/or application of the structure in which the roofing system 70 is used. More detailed information regarding the bonding material 38 is provided below.

FIG. 4 illustrates a sectional view generally in the direction of line 4-4 illustrated in FIG. 1 and FIG. 3 of exemplary roofing system 80. The roofing system 80 includes one or more sandwich panels that form the outer surface of the roof (e.g., sandwich panels 14A and 14B). Likewise, the roofing system 80 includes one or more sandwich panels that support the sandwich panels that form the outer surface of the roof (e.g., sandwich panels 16A and 16B). The sandwich panels 14A and 14B and 16A and 16B are identical to the sandwich panel 14 and 16 discussed above, respectively.

The roofing system of 80 further includes one or more support panels (e.g., support panels 18A-18D, illustrated in FIG. 4. The support panels 18A-18D are identical to the support panel 18 discussed above. The support panels 18A-18D may be formed from composite sandwich panels and have the same structure as described with respect to exemplary sandwich panel 50. Alternatively, the support panels may be formed from any desirable material and/or one or more of the following components: a panel core 56; outer layers 52, 54; wood, particle board, steel, aluminum, etc.

The support panels 18A-18D may have any desired thickness. The thickness of the support panels may vary depending on a variety of variables, including for example: the design of the roof system 80, the structure in which the roof system 80 will be used, environment conditions, size and shape of the roof system, type of bonding material, whether the under-roof construction is to be accessible, etc. Preferably, the support panels have a thickness of not less then the same thickness of the panel in which they support.

As illustrated in FIG. 4, the support panels 18A-18D are spaced apart along one or more portions of the length (L) of the roof. Although not illustrated, the support panels 18A-18D may also be spaced apart along one or more portions of the width (W) of the roof. In some cases, the support panels 18A-18D may be aligned along the width of the roof in section of the roof structure and aligned along the length of the roof in another portion of the roof.

The supports panels 18A-18D may be spaced apart any desired distance (D). The support panels 18A-18D may be spaced apart a predetermined distance (e.g., one meter, two meters, three meters, etc.). The distance in which the support panels 18A-18D may be spaced apart may varying depending on one or more variables, including for example: the design of the roof system 80, the structure in which the roof system 80 will be used, environment conditions, size and shape of the roof system, type of bonding material, whether the under-roof construction is to be accessible, weight, stiffness, strength, etc. In addition, the support panels 18A-18D may be spaced apart a uniform or non-uniform distance (D).

Referring to FIG. 5, another embodiment of the roof system 10, 70 is illustrated. In this embodiment, a channel guide 82 is incorporated into the roofing system 10, 70 for routing liquid (e.g., water, rain, sleet, snow, etc.) that accumulates on the roof. The channel guide 82 may be formed from a first outer surface 84 and a second outer surface 86. The first and second outer surfaces 84, 86 are made from the same materials as discussed above with respect to the first and second outer surfaces 20, 22, 32, 34. The first and second outer surfaces 84, 86 are bonded and/or laminated together using any suitable bonding agent. The channel guide 82 may also be made of one part, e.g., a two layer laminate, without bonding). The channel guide 82 may also be made of a single outer surface layer.

The first outer surface 84 has a guide portion 88 that forms a guide for directing the flow of liquid (e.g., water, rain, snow, etc.) that accumulates on the roof. The guide portion 88 generally extends above the roof panel (e.g., above outer layer 20 of sandwich panel 14) in order to facilitate capture of the water, rain, and/or snow. The guide portion 88 may extend above the roof panel, any desirable amount. It is preferable that the guide portion 88 extends above the outer layer 20 of the sandwich panel 14 a sufficient amount to prevent environmental accumulants from overflowing the guide portion 88.

The first outer surface 84 may also include a securing portion 90. The securing portion 90 may be used to secure the channel guide 82 to one or more sandwich panels (e.g., sandwich panel 14 and/or 16). In one embodiment, illustrated in FIG. 5, the guide portion 88 and the securing portion 90 are planar elements that are configured substantially perpendicular to each other.

As illustrated in FIG. 5, a bonding material 92 may be placed between the securing portion 90 and the sandwich panel 16 to secure the sandwich panel to the roof. In addition, bonding material 92 also may be spread between guide portion 88 and outer layer 34 of the sandwich panels 14, as shown in FIG. 5. Likewise, bonding material 92 also may be spread between guide portion 88 and edge portion 94 of the sandwich panel 16 for additional support and/or to prevent moisture from entering the interface.

The bonding material 92 secures the channel guide 82 to one or more sandwich panels (e.g., sandwich panels 14, 16). The bonding material 92 may also be applied on the first surface 84 of the channel guide 82 and the first outer surface 20 of the sandwich panel 14 to prevent moisture from entering the roofjoint.

It is generally desirable for the channel guide 82 to route or otherwise direct liquid (e.g., water, rain, snow, etc.) that accumulates on a roof to a drainage port or other such device that removes the liquid from the roof and routes the water to a sewer or other desired location. Since a channel guide 82 generally relies on gravity to cause the liquid to flow, it is desirable to install the channel guide along portions of the roof in such a manner to facilitate such flow (e.g., by inclining the channel guide or portions thereof to facilitate flow to a drainage spout or other such structure).

Referring to FIG. 6, an exemplary monolithic structure 100, such as a house, is built from a number of sandwich panels. The house 100 includes four sandwich panels 102, 104, 106, 108 connected together to form a front wall 100 f and two sandwich panels 109, 110 connected together to form a side wall 100 s. The front wall 100 f and side wall 100 s are connected to one another by an angled joint 112. The house 100 has another side wall (not shown) and a rear wall (not shown) and a roof structure 114. The roof structure 114 includes at least two sandwich panels 116 and 118. In addition, the roof structure further includes one or more support panels (not shown) to provide additional stiffness to the roof structure.

The bonding material 38, 92 may rigidly hold or secure one or more sandwich panels together and also may span across and seal the interfaces between sandwich panels to prevent moisture from entering the interface (e.g., interface 96).

The bonding material 38, 92 may be applied in any desirable manner. For example, the bonding material 38, 92 may be applied by injection, spreading, spraying, molding, etc. The bonding material 38, 92 rigidly holds or connects the sandwich panels and also may span across and seal the entranceway to the interface between the sandwich panels. The bonding material 38, 92 may be curved, molded, or formed to create a round corner having a radius. The round corner may distribute forces along one or more building elements. The length of the radius may be about 15 mm (millimeters)-40 mm (millimeters) in length. The length of the radius may be selected based upon the thicknesses of the outer layers of the sandwich panels used to form the monolithic structure 100. The desired ratio of the radius R to the thickness of the outer layers may be about seven to one (7:1), or more, e.g., 8:1 or an even larger ratio. For instance, if the outer layers are about 2 mm (millimeters) thick, the radius would be at least about 14 mm (millimeters), and may be thicker, if desired, or adjusted based upon a desired strength or other factor. In another example, the outer layers may be 3 mm (millimeters) thick and the radius R is at least about 21 mm (millimeters) or more.

The bonding material 38, 92 may be any suitable bonding material such as epoxy, epoxy resin, glue, adhesive, adhering material or another bonding material (these terms may be used interchangeably and equivalently herein). In one embodiment, the bonding material 38, 92 is more flexible or bendable than the sandwich panels, and may, for example, be four or five times more flexible than the panels. The flexibility of the bonding material, therefore, reduces the likelihood that the joints of the monolithic structure will break or split, and also transmits loads from one panel to another, across the joint. The bonding material may include filling components, such as, fiberglass or a fiberglass and resin mixture, and may, for example, be microfiber and Aerosil® material.

The sandwich panels may be customized by cutting and removing a portion of the panel 102, 104 to form an opening for a window 126. The window opening 126 may be cut to any desired size to accommodate the installation of any size window. Similarly, a portion of the panels 102, 104 may be cut and removed to form an opening or doorway 128. Although the sandwich panels (e.g., 102, 104) of FIG. 6 are shown with window 126 and door 128 cutouts, it will be appreciated that the panel can be customized in any manner desired to meet the specifications of an architectural or design plan. The sandwich panels also may be cut in other designs to accommodate other roof, wall, etc. arrangements. It also will be appreciated that while the windows, door and roof are described as being cut from a solid sandwich panel, the openings may be molded or otherwise formed in the panel.

Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. 

1. A roofing system comprising: a first sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a panel core and a first angle edge comprised of an edge portion of the panel core and an edge portion of at least the first outer layer, wherein the first sandwich panel forms at least a portion of a roof structure; a second sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the edge portion of the first sandwich panel is supported, at least in part, by one or more outer surface of the second sandwich panel; one or more support panels secured between the first sandwich panel and the second sandwich panel to provide support for the roof structure.
 2. The roofing system of claim 1, wherein one or more support panels are positioned in a predetermined position between the first sandwich panel and the second sandwich panel.
 3. The roofing system of claim 2, wherein the one or more support panels are secured between the first sandwich panel and the second sandwich panel with a bonding material.
 4. The roofing system of claim 3, wherein the bonding material is an adhesive.
 5. The roofing system of claim 3, wherein a continuous layer of bonding material is applied between the one or more support panels and at least one of the first sandwich panel or the second sandwich panel.
 6. The roofing system of claim 3, wherein bonding material is applied in one or more non-contiguous regions between the one or more support panels and at least one the first sandwich panel or the second sandwich panel.
 7. The roofing system of claim 1, wherein the first sandwich panel is secured at an angle of 45 degrees or less as measured between the first sandwich panel and the second sandwich panel.
 8. The roofing system of claim 1, wherein the one or more support members are formed from at least two materials joined together.
 9. The roofing system of claim 7, wherein the one or more support members are spaced apart to form one or more channels between the first sandwich panel and the second sandwich panel.
 10. The roofing system of claim 9, wherein the one or more support members are spaced apart along an associated pitch of the roof structure.
 11. The roofing system of claim 1, further including a channel guide secured to at least a portion of the second sandwich panel, wherein the channel guide is configured to route moisture deposited on the roof structure in a predetermined manner.
 12. A method of manufacturing a roof structure with one or more support panels, the method comprising: providing a roofing panel that includes a first outer layer and a second outer layer spaced from the first outer layer by a panel core and a first angle edge comprised of an edge portion of the panel core and an edge portion of at least the first outer layer, wherein the roofing panel forms at least a portion of a roof structure; supporting the roofing panel with a base sandwich panel having a first outer layer and a second outer layer spaced from the first outer layer by a second panel core, wherein the base sandwich panel is secured to an associated structure; and securing one or more support panels between the roofing panel and the base panel to provide support for the roof structure.
 13. The method of claim 12, further including applying a continuous layer of bonding material between the one or more support panels and at least one of the roofing panel or the base panel.
 14. The method of, claim 13, further including applying bonding material in one or more non-contiguous regions between the one or more support panels and at least one of the roof panel or the base panel.
 15. The method of claim 12, further including positioning the one or more support panels in predetermined positions between the roofing panel and the base panel.
 16. The method of claim 12, further including securing the roofing panel at an angle of 45 degrees or less as measured between a first axis along a plane of the roofing panel and a second axis along a plane of the base panel.
 17. The method of claim 12, further including securing a channel guide to at least a portion of the base panel, wherein the channel guide is configured to route moisture deposited on the roof structure in a predetermined manner. 